Ceiling mold form



Sept.v21, 1937. P. CARILLI CEILING MOLD FORM Filed May 2l, 1956 2 Sheets-Sheet l Sept. 21, P. CAR|| 2,093,401

CEILING MOLD FORM Filed May 21, 1936 2 Sheets-Sheet 2 l l l l z f/ l l lf, I

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WMI/ l Patented Sept. 21, 1937 UNITED STATES PATENT OFFICE Application May 21,

6 Claims.

My invention relates to forms for use in molding poured concrete ceilings and floors such as are made with two sets of ribs or beams disposed at right angles to each other.

The invention has for its object to provide an improved molding form of the class referred toand also to provide an improved mold form or tile unit for use in constructing ceilings and floors of the class described.

To these ends I have provided the improved form and tile unit therefor as set forth in the following description, the several novel features of the invention being separately pointed out and dened in the claims at the close thereof.

' In the accompanying draWings:-

Figure 1 is a vertical sectional view of a mold form structure constructed in accordance with this invention.

Figure 2 is a vertical sectional View of a ceiling produced by use of the mold form structure shown in Fig. 1. Y

Figure 3 is a top plan view of the mold form shown in'Fig. 1 with the upper sections of the tile units, hereinafter referred to, removed.

Figure 4 is a section on lineA-d of Fig. 3I through the base section of one of the tile units hereinafter referred to.

Figure 5 is a top plan view of the upper section of the tile unit hereinafter referred to.

Figure 6 is a perspective view of one of the chairs hereinafter referred to.

Figure 7 illustrates a modified form of mold unit.

yFigure 8 illustrates another form of chair and is hereinafter described.

n In constructing beamed concrete ceilings, or combined ceilings and floors, it has been common practice to erect a temporary wooden structure including a flooring at its top on which were arranged a multiplicity of tiles on to and around which the concrete was poured. said tiles being disposed in two sets of separated rows at right angles to each otherlso as to provide the under side of the ceiling with two sets of concrete beams` likewise disposed at right angles to each other. Usually the tiles referred to were permanently embedded within or inseparably associated with the concrete of the finished structure.

My -invention provides a tile or form unit com prising va rectangular sheet metal base section I and a hollow upper section which may be a sheet metal dome or cup-shaped element as shown 'at vII in Fig. 1 or which may consist of 1936, serieu No. 80,939

two blocks l2 made from cinder, slag or equivalent material, as shown in Fig. 7.

The sheet metal base section I0 is pressed or molded so as to provide the same with a flat elevated and preferably rectangular horizontal 5' top wall I3,`Fig. 4, bordered by four downwardly and outwardly sloping side walls I4, and with a rectangular outwardly extending horizontal mar# ginal flange I 5 at the bases of the side walls' I4.

The top wall I3 of base Il) is made with a'plu- 10 rality of upstanding lugs I5' disposed adjacent to, but spaced inwardly a short distance away from, the four sides of said top wall so as to closely surround the lower portion of the upper section `lI of Fig. 1, or I2I2 of Fig. 7. These lugs may conveniently be provided by striking up portions of the top wall I3 as shown.

At each corner thereof the ange I5 is cut away slightly as at I6, Fig. 3, for a purpose which will The upper section Il of the tile or form unit may also be made from sheet metal and is of i inverted cup-shape, the chime or bottom thereof being provided with an inwardly extending flange I 'I to seat flatwise on the top wall I3 of base section I Il just inside of the lugs I5 by which it is surrounded. It will therefore be clear that the lugs I5 accurately lposition the upper section II and securely hold the same against displacement when the concrete is poured.

In `order to provide for removal of the upper section II` from the ceiling after the concrete has set the four side walls I8 Vthereof are made 'to slope downwardly and outwardly from the top 35 wall I9 of sai-d section, while the sloping side walls I4 of the base section I Il provide for removal of the latter from the completed ceiling. Thus my new unit as illustrated in Figs. lto 6, inclusive, does not form a permanent part of the 40 ceiling and can be used repeatedly in constructing other ceilings.

Inlconstructing a ceiling by means of a number of units constructed as above described a Wooden form-supporting structure is erected upon the floor ybelow the proposed ceiling, and as shown in Fig. 1 this structure may comprise a plurality of posts 2U to the upper ends of which are secured stringers 2I. The posts 20 and stringers 2| may be made from lumber measuring 3 x 4", 50A for example.

On top of the stringers 2l are provided other transversely disposed stringers 22 which are uniformly spaced-apart ya distancevequal to the overall Width of the Vbase section ID of the above deappear later. 2.0,-

ceiling structure is to support.

scribed tile or form unit. These stringers 22 may be made from lumber measuring, for example, 2" X 6 in cross-section.

A number of tile units are then assembled in position upon the stringers 22 with the edges of their flanges I5 abutting as shown in Figs. l and 3. These units are relatively disposed in two sets of parallel rows which are at right angles and when thus assembled the cut-away corners I6 of the edges of the flanges I5 provide small apertures as shown in Fig. 3 through which nails 23, Fig. 1, are driven into the stringers 22 thereby Xing the units in position thereon.

Thus thenails 23 hold the base sections of the units against displacement on the stringers 22 while the lugs I5 position the upper sections II on the lower sections and hold the saine against displacement thereon. Y

After the molding form is thus assembled upon the temporary supporting structure a number of reinforcement-supporting chairs 24 are placed in position across thelower portions of a plurality of beam-forming channels 25 now existing between adjacent units, one end of each chair resting upon the outer marginal portion of one base section I Il an-d its other end resting upon the outer marginal portion of the opposite base section.

E'ach chair may consist of a metal strip shaped to provide two pockets 26 upon its top side, Fig. 6, each adapted to be occupied by a metal reinforcing bar 21. These bars arethus supported by the chairs so that when the concrete is poured they are surrounded by the latter. 35

The concrete 28 'is now poured or otherwise deposited upon the molding form made up of the assembled units III-II to the desired depth which usually is proportionate to the load the When the "concrete is set the temporary wooden supporting structure 2ll-2I-22 and the tile sections IIJ and -'I I are removed leaving a reinforced cellular concrete ceilingstructure as shown in Fig. 2.

The removal of each unit leaves a recess or pocket which is countersunk at its outer lower open end, said countersink being adapted to receive within it a panel 29 of acoustical board,-

mill board or other suitable material which is secured in position therein by cement or otherwise.

When the base section I0 of the unit shown in Fig-'7 is removed the upper section I2, I2 thereof remains permanently incorporated Vwithin the ceiling structure and may be covered and hidden from View by a panel such as 29, Fig. 2, fixed in position within the countersink vacated by the base section.

When the above described mold unit is removed from the finished ceiling the opposite' end portions of each reinforcement-supporting chair 24 are exposed and accessible at the shoulders produced by the countersinks into which said ends extend and if desired these portions may be provided with threaded apertures as shown in Fig. 6 or otherwise adapted to coact with fastening devices by means of which the panels 29 are secured in position within the countersinks.

If desired molding strips indicated by dotted lines at 30, Fig. 2, may be fixed in position by means of nails driven therethrough and into panels 29 so as to cover the joints between said panels and the beams of the ceiling.

The chair 24 illustrated in Fig. 8 is likewise formed with an aperture near each end thereof, like the apertures 32 of Fig. 6 except that they need not be threaded, and when the chairs 24,

Fig. 8 are placed in position on the base sections IIl of the form as indicated by broken lines in Fig. 3, the apertures of each chair are registered with the two oppositely disposed apertures 33 provided through the top walls of the two base sections by which the chair is supported and a split self-clinching nail 3I is placed in position within each registering pair of apertures.

It will therefore be clear that when the ceiling is finished and the form elements or units are removed the split Shanks of the nails 3I are permanently and rigidly held in position within the` countersink by the chair and by the cement in which their heads are embedded.

These nails are provided to hold the panels 29 in position within the countersinks, each panel being driven into its countersink so that it is impaled upon the nails 3| of the latter, and the shank of each nail spreading and clinching itself within the material of the panel as the latter is driven into position.

The fiange I1 of the upper section serves mainly to reinforce and stiffen the side walls of the latter, but it also is useful as means by which the upper section can be forcibly removed from the finished ceiling.

What I claim is:

1. A mold unit of the character described comprising a base section of relatively small height and also of relatively large area as viewed in plan for forming a panel-receiving countersink in the ceiling from which it is removable when the ceiling is finished, said basev section consisting of v separably supported by said base section and positioned relatively thereto by said upstanding lugs.

2. A mold unit of the character described comprising a base section of relatively small height and also of relatively large area as viewed in plan for forming a panel-receiving countersink in the ceiling from which it is removable when the ceiling is finished, said base section consisting of a single piece of sheet metal pressed to provide the same with a rectangular outer marginal iiange, with an elevated flat top wall and with side walls connecting said top wall and fiange which slope upwardly and inwardly from the latter to said top wall to afford draft for the removal of said base section from the finished ceiling, andan upper section separably supported by said base section consisting of a single piece of sheet metal pressed into the form of a dome that is tapered from its base to its top to afford draft for removal thereof from the finished ceiling, the chime of said dome resting on the elevated top wall of said base section, and means for positioning said upper section on said base section and for holding said sections against rela.- tive displacement laterally when the concrete is deposited on said unit.

3. A mold unit of the character described constructed in accordance with claim 2 wherein said upper sectionis made at its base with an inwardly extending flange for use in removing said upper section from the finished concrete structure. Y 4. A mold for use in constructing cellular concrete ceilings and floors, said mold consisting of a plurality of mold units arranged side by side each in abutting relationship on all sides thereof with the units by which it is surrounded so that said units collectivelyprovideacompletehorizontal support for the concrete, each of said units comprising a sheet metal base section of relatively small height and also of relatively large area as viewed in plan for forming a shallow shouldered panelreceiving countersink in the concrete structure from which it is removable when said structure is finished, said base section being made with an angular marginal flange to abut the corresponding flanges of the base sections of the adjacent surrounding units and with side surfaces which extend upwardly from said flange to a flat top surface provided on said base section, and a hollow upper section seated upon said flat top surface and of relatively greater height but smaller in area as viewed in plan than said top surface; lugs projecting upwardly from said flat top surface separably and telescopically engaging said upper section to position the latter and hold the same against lateral displacement in any direction on said base section when the concrete is deposited upon the mold, and means for supporting said units from below.

5. A mold for use in constructing cellular concrete ceilings and floors said mold being constructed in accordance with claim 4 and including reinforcement-supporting chairs each consisting of a bar resting at its one end upon the marginal portion of the ilat top surface of one of said sections and at its opposite end upon the marginal portion of the flat top surface of an adjacent base section.

6. A sheet metal mold section formed with a flat rectangular marginal flange bordering an upstanding wall which extends throughout the circuit of said flange and said upstanding wall bordering a flat top wall that is parallel with said flange, said top wall being made with upstanding lugs near its outer limits to telescopically engage with an upper mold section thereby to hold the latter against displacement laterally in any direction while the concrete is being deposited upon said section, a multiplicity of said sections being adapted to be arranged side by side with the flange of each in abutting relationship with the flanges of the sections by which it is surf rounded so that said sections collectively provide a complete support for the concrete.

PASQUALE CARILLI. 

